Metallurgy and Processing of High-Integrity Light Metal Pressure Castings

Very sophisticated pressure casting equipment, such as High Pressure Die Casting (HPDC) machines with hydraulic shot control, Vertical Squeeze Casting machines and various Semi-solid Casting machines are used in modern foundries today. Nevertheless, the increasing geometrical complexity and technical requirements of light metal pressure castings have rendered process stability and castability a permanent issue for foundry men. The castings should be simultaneously light, strong, ductile, weldable, heat treatable, and pressure tight. In order to achieve these goals a process chain approach comprising a significant materials science component must be applied to aid product, alloy and process improvement. The contents of this book involve just such a process chain approach. In addition to the principles of pressure casting, the effects of melt quality, alloy composition, filling conditions, and even post-processing aspects such as heat treatment are addressed. Parameters affecting process stability and productivity are also discussed. It is hoped that this book will help foundry management and foundry men on the shop floor to achieve future improvements in pressure casting.